Primary side constant output current controller with highly improved accuracy

ABSTRACT

A comparing circuit and a control loop are used to maintain the peak level of current flowing through an inductor of a flyback converter. An inductor switch control signal controls an inductor switch through which the inductor current flows. The inductor current increases at a ramp-up rate during a ramp time and stops increasing at the end of the ramp time. The comparing circuit generates a timing signal that indicates a target time at which the inductor current would reach a predetermined current limit if the inductor current continued to increase at the ramp-up rate. The control loop then receives the timing signal and compares the target time to the end of the ramp time. The pulse width of the inductor switch control signal is increased when the target time occurs after the end of the ramp time. Adjusting the pulse width controls the peak of the inductor current.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit under 35 U.S.C. §119 of provisionalapplication Ser. No. 60/889,268, entitled “Primary Side Constant OutputCurrent Controller With Highly Improved Accuracy”, filed Feb. 10, 2007.The subject matter of provisional application Ser. No. 60/889,268 isincorporated herein by reference.

TECHNICAL FIELD

The present invention relates generally to the field of power conversionand, more particularly, to switch mode power supply circuits thatregulate output current and voltage.

BACKGROUND

Over the years, various integrated circuit chips have been developed andused to build constant current, constant voltage flyback power suppliesfor many power supply applications, including off-line AC/DC powersupply adapters, chargers, and standby power supplies for portableelectronic equipment.

FIG. 1 (prior art) illustrates an exemplary prior art constant outputcurrent flyback converter 10 controlled on the secondary side of atransformer 11. Transformer 11 has three windings: a primary-sidewinding Lp, a secondary-side winding Ls, and an auxiliary winding La.Converter 10 has a primary switch 12, which is an external metal-oxidesemiconductor field-effect transistor (MOSFET). Flyback converter 10also has a secondary side resistor 13 that represents the resistive lossof the copper windings of transformer 11, a first current sense resistor14, a secondary rectifier 15, an output capacitor 16, an optical coupler17, a second current sense resistor 18, a bias resistor 19, a currentlimit transistor 20, and a conventional peak-current-mode pulse widthmodulation (PWM) control integrated circuit (IC) 21. The initialstart-up energy for control IC 21 is provided by a resistor 22 and acapacitor 23. Once flyback converter 10 is stable, auxiliary winding Laof transformer 11 powers IC 21 via a rectifier 24. Second current senseresistor 18 and transistor 20 control the output current. Transistor 20regulates the voltage across second current sense resistor 18 to apreset base-emitter voltage (VBE). The output current of flybackconverter 10 is, therefore, equal to VBE divided by the resistance ofsecond current sense resistor 18. One disadvantage of flyback converter10 is that both the base-emitter voltage and the output current varywith temperature. Moreover, the base-emitter voltage causes significantpower loss. In addition, flyback converter 10 is costly because thesafety-approved optical coupler 17 adds a significant cost to theoverall material cost.

FIG. 2A (prior art) illustrates a second exemplary prior art constantoutput current flyback converter 25 controlled on the primary side oftransformer 11. Flyback converter 25 does not include the opticalcoupler integrated circuit of flyback converter 10, nor the currentsense components on the secondary side of the transformer. Flybackconverter 25, however, suffers from output current inaccuracy because(a) the primary inductor of the transformer varies, and (b) the actualpeak current of the primary inductor Lp differs slightly from thatindicated by the current sense voltage Vcs divided by the resistance ofresistor 14. Variations in the primary inductor of transformer 11 causethe output current of flyback converter 25 to vary with the primaryinductance. The actual peak current of the primary inductor Lp differsslightly from that set by the sense resistor voltage Vcs divided by theresistance of resistor 14 due to propagation delay of a current sensecomparator in control IC 21, as well as the delay associated with theturning off of external MOSFET 12.

FIG. 2B (prior art) illustrates peak current detection errors in flybackconverter 25 of FIG. 2A. The on/off gate drive voltage of main switch 12in FIG. 2A is illustrated by the waveform GATE. At time T1, GATE goeshigh, and MOSFET 12 turns on. The primary inductor current ILP ramps uplinearly at the rate dI/dt=Vp/Lp, where Vp is the voltage across theprimary inductor, and Lp is the inductance of the primary inductor.Thus, the sense resistor voltage Vcs will also ramp up proportionally.The sensed voltage signal Vcs reaches Vref at T2, at which time it isassumed that the peak primary current Ip is Vref/Rcs, where Rcs is theresistance of current sense resistor 14. However, due to the propagationdelay of the current limit comparator and the delays in pulse widthmodulation (PWM) logic and drivers in control IC 21, GATE does not golow and turn off until T3. The period (T3-T2) is the GATE turn-offdelay. The drain of MOSFET 12 will fly up when the switch turns off atT3, but the primary inductor current I_(LP) will continue to rise untilthe drain voltage of MOSFET 12 reaches VIN at time T4 and the polarityof the voltage across the primary inductor Lp reverses. As a result, thefinal primary inductor peak current is Ipf instead of Ip. Unfortunately,the final primary inductor peak current Ipf varies because (T3-T2) and(T4-T3) vary with temperature, input line voltage, IC processvariations, external component tolerances, and printed circuit board(PCB) layout variations. All of these variations produce errors thatdetract from the accuracy of the regulation of the overall outputcurrent by flyback converter 25.

In view of the foregoing, a method is sought for regulating the outputcurrent of a flyback converter that both employs primary side controland that is relatively low cost. The method should overcome thelimitations of the prior art described above by using a minimal numberof integrated circuits and external components. The method shouldeliminate the need for a secondary circuit and an optical coupler.Moreover, the output current of the flyback converter should be largelyinsensitive to temperature, input line voltage, IC process variation,external component value tolerances, and PCB layout variations.

SUMMARY

A flyback converter includes a transformer that converts an inputvoltage into a different output voltage. In one embodiment, the inputvoltage is the voltage from a wall outlet, and the output voltage isused to charge a portable electronic consumer device. When a main powerswitch in the converter is turned on, a current starts flowing throughthe primary winding of the transformer. After current ramps up throughthe primary winding to a peak magnitude and is then cut, a collapsingmagnetic field around the primary winding transfers energy to asecondary winding. The energy transferred to the secondary winding isoutput from the flyback converter as the output current with thedifferent output voltage. In some applications, such as charging anelectronic consumer device, it is desirable for the output current to bemaintained at a constant level.

The flyback converter generates a constant output current at a currentlevel that falls within a specified tolerance despite any deviation ofthe actual inductance of the windings from the stated inductance thatthe windings are supposed to exhibit. In addition, the flyback convertergenerates a constant output current by adjusting the peak currentflowing through the primary winding to an appropriate level. The flybackconverter adjusts the peak current flowing through the primary windingto compensate for propagation delays and parasitics in the controlcircuits that would otherwise prevent the accurate detection of when thecurrent flowing through the primary winding has reached its peak.

A comparing circuit and a control loop in an adaptive current limiterare used to maintain the peak current at the appropriate level. Aninductor switch is controlled by an inductor switch control signal thathas a pulse width. The current that flows through the inductor increasesat a ramp-up rate during a ramp time until the ramp time ends at a firsttime. At the first time, the inductor current stops increasing. Thecomparing circuit generates a timing signal that indicates a target timeat which the inductor current would reach a predetermined current limitif the inductor current continued to increase at the ramp-up rate. Thecontrol loop then receives the timing signal and compares the first timeto the target time.

A pulse width generator generates a pulse width signal that controls thepulse width of the inductor switch control signal. The pulse widthgenerator increases the pulse width when the first time occurs beforethe target time. The pulse width is adjusted so that the first time andthe target time occur simultaneously. By adjusting the pulse width, thepeak magnitude of the current flowing through the inductor is controlledat an appropriate level.

In another embodiment, a comparing circuit receives a feedback signalindicative of a first time at which an inductor current flowing throughan inductor stops increasing. The comparing circuit also receives aswitch signal indicative of a ramp-up rate at which the inductor currentincreases. The comparing circuit generates a timing signal thatindicates a target time at which the inductor current would reach apredetermined current limit if the inductor current continued toincrease at the ramp-up rate. An inductor switch control signal with apulse width is then generated. The pulse width of the inductor switchcontrol signal is controlled such that the first time and the targettime occur simultaneously. The pulse width is decreased when the firsttime occurs after the target time and increased when the first timeoccurs before the target time.

Other embodiments and advantages are described in the detaileddescription below. This summary does not purport to define theinvention. The invention is defined by the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, where like numerals indicate like components,illustrate embodiments of the invention.

FIG. 1 (prior art) is a simplified schematic diagram of a conventionalconstant output current flyback converter that is controlled on thesecondary side.

FIG. 2A (prior art) is a simplified schematic diagram of a conventionalconstant output current flyback converter that is controlled on theprimary side.

FIG. 2B (prior art) are waveform diagrams illustrating peak currentdetection errors in the constant output current flyback converter ofFIG. 2A.

FIG. 3 is a simplified schematic diagram of a flyback converter with acomparing circuit and a control loop in accordance with an embodiment ofthe invention.

FIG. 4 is a flowchart of a method for controlling the peak currentflowing through an inductor of a flyback converter.

FIG. 5 is a simplified schematic diagram of a constant output currentand voltage flyback converter controlled by the primary side, includinga pulse width modulation controller integrated circuit.

FIG. 6 is a more detailed schematic diagram of the pulse widthmodulation controller integrated circuit of FIG. 5, including anoscillator and an adaptive current limiter.

FIG. 7 is a more detailed schematic diagram of the oscillator of FIG. 6.

FIG. 8 is a waveform diagram illustrating idealized waveforms of theauxiliary winding voltage, the primary switch current and the secondaryrectifier current operating in Discontinuous Conduction Mode (DCM).

FIG. 9 is a waveform diagram showing idealized timing waveforms of theoscillator in FIG. 6.

FIG. 10 is a waveform diagram showing the operational and timingwaveforms of the adaptive current limiter of FIG. 6.

FIG. 11 is a more detailed schematic diagram of the adaptive currentlimiter of FIG. 6.

FIG. 12 is a more detailed schematic diagram of an alternativeembodiment of the controller integrated circuit of FIG. 6.

FIG. 13 is a schematic diagram of the controller integrated circuit ofFIG. 12 implemented with an external MOSFET and current sense resistor.

FIG. 14 is a schematic diagram of the flyback converter of FIG. 3 inwhich the controller integrated circuit is packaged in an integratedcircuit package.

DETAILED DESCRIPTION

Reference will now be made in detail to some embodiments of theinvention, examples of which are illustrated in the accompanyingdrawings.

FIG. 3 is a diagram of a flyback converter 30 with a comparing circuitand a control loop used to adjust the peak current that flows through aninductor. FIG. 4 is a flowchart illustrating steps 31-35 of a method ofoperation of the flyback converter 30 of FIG. 3. The method controls theoutput current of flyback converter 30 by adjusting the peak currentthat flows through an inductor of the flyback converter 30. Flybackconverter 30 includes a transformer 36, an external NPN bipolartransistor 37, and a controller integrated circuit (IC) 38. Transformer36 includes a primary winding (inductor) 39, a secondary winding 40 andan auxiliary winding 41. Controller IC 38 includes and oscillator 42, anadaptive current limiter 43, an internal main power switch 44,pulse-width-modulation (PWM) logic 45 and a gate driver 46. Adaptivecurrent limiter 43 includes a comparing circuit 47, a control loop 48and a pulse width generator 49.

When main power switch 44 is turned on, an inductor current 50 startsflowing through primary inductor 39. As inductor current 50 ramps upthrough primary inductor 39, a magnetic field is generated thattransfers energy to secondary winding 40 when main power switch 44 isturned off. The energy transferred to secondary winding 40 is outputfrom flyback converter 30 as an output current (I_(OUT)). In someapplications, it is desirable for the output current (I_(OUT)) offlyback converter 30 to be maintained at a constant level. The outputcurrent (I_(OUT)) is dependent on at least three factors: (i) the peakmagnitude of inductor current 50, (ii) the inductance (L_(P)) of primaryinductor 39, and (iii) the frequency (f_(OSC)) at which main powerswitch 44 is turned on allowing current to ramp up through primaryinductor 39. To the extent that the inductance (L_(P)) of primaryinductor 39 deviates from a stated nominal magnitude due to variationsin the manufacturing processes of transformer 36, the output current(I_(OUT)) of individual converters will vary. For example, if the wirethat forms the inductor is not of uniform diameter, or if the wire isnot wound in a consistent manner, the actual inductance of individualprimary inductors will vary. In addition, propagation delays andparasitics in the components that control inductor current 50 using mainpower switch 44 cause the peak current (I_(P)) through primary inductor39 to vary. For example, the propagation delays are process, temperatureand voltage dependent.

FIG. 4 describes a method for adjusting the peak current (I_(P)) flowingthrough primary inductor 39 in order to maintain a constant outputcurrent (I_(OUT)) from flyback converter 30 despite changes inpropagation delays and parasitics that are process, temperature andvoltage dependent. In addition, peak current (I_(P)) is adjusted tocompensate for non-uniform inductance (L_(P)) of primary inductor 39 dueto process variations. Moreover, a method is described for compensatingfor non-uniform inductance (L_(P)) by adjusting the frequency (f_(OSC))at which main power switch 44 turns on allowing inductor current 50 toramp up through primary inductor 39. Thus, output current (I_(OUT)) ismaintained at a constant magnitude by adjusting either or both the peakinductor current (I_(P)) and the switching frequency (f_(OSC)) at whichinductor current 50 ramps up through primary inductor 39.

In a first step (step 31), adaptive current limiter 43 receives afeedback signal 51 indicating when inductor current 50 stops increasingin magnitude through primary inductor 39. Both comparing circuit 47 andcontrol loop 48 of adaptive current limiter 43 receive feedback signal51 from oscillator 42. Inductor current 50 stops ramping up throughprimary inductor 39 at a first time. Oscillator 42 uses an auxiliaryfeedback signal 52 to generate feedback signal 51 as well as a switchingfrequency signal 53. Auxiliary feedback signal 52 is generated using thevoltage on a node of auxiliary winding 41. As inductor current 50 rampsup through primary inductor 39, a magnetic field is generated thattransfers energy to auxiliary winding 41 and generates the voltage onthe node of auxiliary winding 41.

In a second step (step 32), comparing circuit 47 receives a switchsignal 54 indicative of a ramp-up rate at which inductor current 50increases through primary inductor 39. Switch signal 54 is obtained fromthe emitter of external NPN bipolar transistor 37 via a switch terminal(SW) of controller IC 38. Inductor current 50 which ramps up throughprimary inductor 39 also flows through NPN bipolar transistor 37 and theswitch terminal (SW) of controller IC 38. Although switch signal 54 isderived from the NPN emitter current flowing through main power switch44 in FIG. 3, other alternative embodiments can be used to generateswitch signal 54, for example by using a sense resistor in the source ofmain power switch 44 or a resistor in the source of a sense MOSFETconnected in parallel with main power switch 44.

In a third step (step 33), comparing circuit 47 generates a timingsignal 55 that indicates a target time at which inductor current 50would reach a predetermined current limit if inductor current 50continued to increase at the ramp-up rate.

In a fourth step (step 34), controller IC 38 generates an inductorswitch control signal 56 that has a pulse width. Inductor switch controlsignal 56 controls the gate of main power switch 44, through whichinductor current 50 flows. Gate driver 46 generates inductor switchcontrol signal 56 using an “N-channel on” (Nchon) signal 57. PWM logic45 generates the N-channel on signal 57 using the switching frequencysignal 53 received from oscillator 42 and a pulse width signal 58received from pulse width generator 49. Switching frequency signal 53provides the frequency of the pulses of inductor switch control signal56, and pulse width signal 58 provides the duration of the pulse widthof inductor switch control signal 56. Pulse width generator 49 generatespulse width signal 58 using a time error signal 59 received from controlloop 48.

In a fifth step (step 35), adaptive current limiter 43 controls thepulse width of inductor switch control signal 56 such that the firsttime (at which inductor current 50 stops increasing through primaryinductor 39) and the target time (at which inductor current 50 wouldreach the predetermined current limit) occur simultaneously. In oneembodiment, adaptive current limiter 43 controls the pulse width ofinductor switch control signal 56, whereas in another embodimentadaptive current limiter 43 controls the pulse width of pulse widthsignal 58 or Nchon signal 57. The first time and the target time can beadjusted to occur simultaneously by controlling the pulse width of anyof pulse width signal 58, Nchon signal 57 or inductor switch controlsignal 56. By adaptively controlling the pulse width, the peak inductorcurrent (I_(P)) is adjusted so as to maintain a constant output current(I_(OUT)) of flyback converter 30.

FIG. 5 is a higher level diagram of flyback converter 30 of FIG. 3.Flyback converter 30 is an accurate and yet low-cost power supplyconverter that is controlled from the primary transformer side and whoseoutput current is regulated. FIG. 5 shows that flyback converter 30 hasno secondary side control circuit and no optical coupler, as are presentin the described prior art. The only feedback from the secondary sideused by flyback converter 30 to control the output current and voltageis feedback from the magnetic coupling of auxiliary winding 41 andsecondary winding 40. In addition to saving cost, the lower componentcount resulting from the lack of a secondary side control circuit andoptical coupler improves the reliability of flyback converter 30.

Two factors that affect the accuracy of regulating the output current offlyback converter 30 are: (a) the variation in the primary inductorwinding 39 of transformer 36, and (b) the inaccuracy in detecting of thepeak current (I_(P)) of primary inductor 39. The actual inductance(L_(P)) of the primary magnetic inductor typically varies by about ±20%.The peak current (I_(P)) of the primary magnetic inductor is typicallynot accurately detected because of propagation delays in current sensecomparators, PWM logic, gate drivers in controller ICs, because ofturn-off delays of the primary power switch, and because of parasiticsassociated with the drain, in the case of MOSFETs, or the collector, inthe case of NPN transistors, of the primary power switch. In addition,the accuracy of peak current detection is reduced by variations intemperature, voltage, IC process, PCB layout, and external-componentvalue-dependent parasitic sources. Flyback converter 30 compensates forthe deviations from a stated nominal magnitude of the inductance of theprimary inductor by varying the oscillator frequency (f_(OSC)) of mainpower switch 44 inversely to the deviation in the inductance (L_(P)).Flyback converter 30 compensates for the propagation delay andparasitics that make peak current detection difficult by detecting andcontrolling the peak current of primary magnetic inductor 39 usingadaptive current limiter 43 with control loop 48. Moreover, flybackconverter 30 is implemented in an emitter switching configuration withprimary-side control in order to reduce cost.

Flyback converter 30 of FIG. 5 outputs a constant current and voltage byoperating in two modes: a constant (peak) current mode and aconstant-voltage mode. Primary winding 39 of transformer 36 has Npturns; secondary winding 40 has Ns turns; and auxiliary winding 41 hasNa turns. FIG. 5 shows a secondary side resistor 60 that represents theresistive loss of the copper windings of transformer 36. Flybackconverter 30 has a secondary-side rectifier 61, an output capacitor 62,and controller IC 38. Controller IC 38 is a peak-current-mode pulsewidth modulation (PWM) controller. The initial start-up energy forcontroller IC 38 is provided by a resistor 63 and a capacitor 64. Onceflyback converter 30 is stable, auxiliary winding 41 of transformer 36powers controller IC 38 via a rectifier 65.

A feedback bond pad FB 66 of controller IC 38 on the primary side oftransformer 36 receives an indication of the output voltage (V_(OUT)) ofsecondary winding 40. Auxiliary feedback signal 52 on feedback bond padFB 66 is obtained by passing the voltage (V_(AUX)) 67 on a node ofauxiliary winding 41 through a voltage divider resistor network thatincludes a first feedback resistor (R_(FB1)) 68 and a second feedbackresistor (R_(FB2)) 69. Auxiliary feedback signal 52 is also used tocompute the on-time and the actual ramp-up time of the primary inductor.

The embodiment of flyback converter 30 shown in FIG. 5 is used inapplications requiring higher output power or higher switching frequencyand uses external power-handling components, such as NPN bipolartransistor 37. The base of NPN bipolar transistor 37 is coupled to adiode 70 and a resistor 71. Other embodiments of flyback converter 30that are used in low-power applications have no external bipolartransistor, MOSFET power switch or current sense circuit, all of whichcan be integrated into the integrated circuit 38.

NPN bipolar transistor 37 cooperates with controller IC 38 in an emitterswitching configuration as shown in the FIG. 5. External NPN bipolartransistor 37 acts as a switch to primary winding 39. In thisconfiguration, an internal circuit in controller IC 38 drives theemitter of external bipolar transistor 37. In other embodiments, tofurther increase the power handling capability and switching frequency,an external MOSFET is used as the main switch instead of bipolartransistor 37. Generally, the frequency capability of bipolar transistor37 is limited by the NPN base charge/discharge time, and the high powercapability of bipolar transistor 37 is limited by the base driveresistor. Thus, using bipolar transistor 37 is appropriate forapplications that do not require very high power or switching frequency.

Using a sense resistor to detect the peak current of the primaryinductor, as done in the prior art, would be impractical because thecurrent in the sense resistor of the prior art would be equal to the NPNemitter current, which is comprised of both the actual inductor currentflowing in the collector as well as the base current of bipolartransistor 37. Despite this complication, using an NPN transistorinstead of a MOSFET is desirable because the cost of a bipolartransistor is typically much lower than that of a high voltage MOSFET,even though the bipolar transistor contributes additional significanterror terms that depend on transistor characteristics, such as currentgain (Beta) and saturation effects. Current gain and saturation aredifficult to control and vary considerably over process, temperature,voltage, and external component value changes.

FIG. 6 shows controller IC 38 in more detail. Controller IC 38 includesadaptive current limiter 43 that compensates for control error in thedetection of the peak current (I_(P)) of primary inductor 39. Adaptivecurrent limiter 43 is a low-cost solution to correcting errors in peakcurrent detection and does not substantially compromise performance.

Adaptive current limiter 43 is used to make the peak current (I_(P)) ofprimary inductor 39 constant despite all system variations. The turn-offof internal power MOSFET 44 is adjusted using control loop 48 such thatthe total ramp-up time (T_(RAMP)) of primary inductor 39 correspondsprecisely to the time required for primary inductor 39 to ramp-up to apre-determined peak current limit (I_(LIM)). The total ramp-up time(T_(RAMP)) includes: (a) the internal on-time of main power switch 44,(b) the base discharge time of bipolar transistor 37, and (c) thecollector rise time of bipolar transistor 37. The total ramp-up time(T_(RAMP)) is forced to equal twice the time it takes to ramp-up toexactly half of the limit (I_(LIM)) of the peak current flowing throughprimary winding 39. Although the ratio 2:1 is used in this example, inother embodiments other ratios can also be used. In many practicalapplications, the 2:1 ratio performs reasonably well, consideringaccuracy and real world implementation details (e.g., device layoutmatching). Other suitable ratios, such as 3:1, can be used dependingupon the needs of the particular application. Control loop 48 adaptivelydrives the actual ramp-up time (T_(RAMP)) of primary inductor 39 to beequal to a reference time.

There are many alternate applications where the peak inductor currentdoes not need to be held substantially constant despite all systemvariations. One application of AC/DC power supply converters andadapters that does not require substantially constant peak inductorcurrent is the limiting of output current or power to protect againstfault conditions. Such an application does not necessarily need toregulate output current to a very high accuracy, as do AC/DC off-linechargers.

A regulator 72 provides an internal power supply and a reference voltageV_(REF) to controller IC 38. In one embodiment, regulator 72 receives afifteen-volt V_(DD) voltage generated during startup by resistor 63 andcapacitor 64 and sustained after startup by auxiliary winding 41 andrectifier 65, and outputs a five-volt power signal that is received byadaptive current limiter 43. An under-voltage lockout circuit (UVLO) 73monitors the V_(DD) voltage supplied to controller IC 38 and enables thenormal operation of controller IC 38 when V_(DD) reaches theunder-voltage lockout turn-on threshold. In this example, theunder-voltage lockout turn-on threshold is nineteen volts, and theunder-voltage lockout turn-off threshold is eight volts. If V_(DD) dropsto the under-voltage lockout turn-off threshold, then controller IC 38is disabled. An indication of the output voltage of secondary winding 40of transformer 36 is fed back via auxiliary winding 41 and feedback bondpad FB 66 to controller IC 38. Auxiliary feedback signal 52 is comparedto the reference voltage V_(REF) generated by regulator 72 to produce anerror signal, which is amplified by a pre-amplifier 74, sampled by asampler 75, and fed to a PWM error amplifier 76, which further amplifiesthe error signal. A twice amplified error signal 77 is output by erroramplifier 76. An internal compensation network for error amplifier 76 isformed by a resistor 78 and the capacitors 79 and 80. An errorcomparator 81 receives error amplifier output signal 77 and serves as apulse-width modulation comparator for the constant-voltage mode offlyback converter 30.

In addition to pre-amplifier 74, both oscillator and T_(RAMP) detector42 and a frequency modulator (FMOD) 82 receive auxiliary feedback signal52 from feedback bond pad FB 66. FMOD 82 senses the voltage of auxiliaryfeedback signal 52 and generates a bias current for oscillator andT_(RAMP) detector 42. The bias current output by FMOD 82 varies with thevoltage of auxiliary feedback signal 52, thereby adjusting theoscillator frequency (f_(OSC)) as the output voltage (V_(OUT)) offlyback converter 30 changes in order to maintain a constant outputcurrent. Oscillator 42 includes a T_(RAMP) detection circuit thatdetects the actual time that the current in primary inductor 39 isramping up (T_(RAMP)). The T_(RAMP) detection circuit determines thetotal ramp-up time based on the voltage waveform (V_(AUX)) 67 ofauxiliary winding 41 that is divided by the voltage divider of resistors68 and 69. Oscillator 42 generates the frequency for the pulse-widthmodulation that drives main power switch 44.

The voltage of auxiliary feedback signal 52 depends on the ratio of theinductance of auxiliary inductor 41 to that of primary inductor 39 andsecondary inductor 40 and is used as the reference voltage foroscillator 42. Thus, in addition to peak current (I_(P)) the oscillatorfrequency (f_(OSC)) also compensates for variations in the inductance ofprimary inductor 39. In addition to the embodiment of FIG. 6, otheralternate topologies may be used to modify the characteristics ofoscillator 42 in order to compensate for variations in the primaryinductance of transformer 36.

PWM logic circuit 45 generates the desired pulse-width modulationwaveform by utilizing: (a) current-mode PWM control when regulatingoutput voltage, and (b) cycle-by-cycle adaptive current limiting whenregulating output current. The Nchon signal 57 output by PWM logic 45 isreceived by gate driver 46. Gate driver 46 is a relatively high-speedMOSFET gate driver. The inductor switch control signal 56 output by gatedriver 46 is received by main power switch 44, as well as by a smallerscaled internal MOSFET 83. The smaller internal MOSFET 83 and a resistor84 form a current sense circuit. The sensed current is amplified by acurrent sense amplifier 85 and is converted to a voltage signal. Thevoltage signal is compared by error comparator 81 to error amplifieroutput signal 77 output by PWM error amplifier 76. Error comparator 81outputs a regulation signal 86 that is used to set the on-time of mainpower switch 44. In the constant-voltage mode of operation when theoutput current of flyback converter 30 is less than the maximum outputcurrent limit, regulation signal 86 is used to regulate a constantoutput voltage. In the constant-current mode of operation, outputcurrent regulation is maintained by adaptive current limiter 43 limitingthe peak current (I_(P)) of primary inductor 39 when the output current(I_(OUT)) reaches a pre-determined current limit (I_(LIM)). Adaptivecurrent limiter 43 limits the peak current independent of temperature,input line voltage, IC and external component tolerance changes, and PCBlayout variations.

Cord correction circuit 87 receives error amplifier output signal 77 andgenerates a cord correction signal 88 whose voltage is proportional tothat of error amplifier output signal 77. Cord correction signal 88 isused to adjust the voltage of auxiliary feedback signal 52 to compensatefor the loss of output voltage caused by the series resistance of thecharger cord of flyback converter 30. Cord resistance compensationprovides a reasonably accurate constant voltage at the end of the cordthat connects flyback converter 30 to the device that is to be chargedor powered, such as a cell phone or a portable media player. Outputvoltage is lost because the voltage at the point of load will have anI·R drop due to the finite series resistance of the cord multiplied bythe output current of the power supply. Primary-side-controlled flybackpower converter 30 relies on the reflected feedback voltage acrosstransformer 36 from secondary winding 40 to auxiliary winding 41 toregulate the output voltage (V_(OUT)), but this reflected voltage doesnot include the I·R voltage drop error resulting from the finite cordresistance. In the constant-voltage mode of operation, the output oferror amplifier 76 is proportional to the output current of flybackconverter 30. Therefore, error amplifier output signal 77 can be used toproduce cord correction signal 88 whose voltage is proportional tooutput current and which can be applied either to the feedback input orto the reference voltage input of pre-amplifier 74 to compensate forcord resistance. In the embodiment of FIG. 6, the correction is appliedto the feedback input of pre-amplifier 74, but the correction can besimilarly applied to the reference voltage input in alternateembodiments.

FIG. 7 shows oscillator and T_(RAMP) detector 42 of controller IC 38 inmore detail. Oscillator 42 includes voltage comparator 89, a delayelement 90, a T_(RAMP) detection circuit 91, three current sources 92,93 and 94, and an oscillator capacitor C_(OSC) 95. T_(RAMP) detectioncircuit 91 determines the total ramp-up time using auxiliary feedbacksignal 52, which provides an indication of the voltage waveform(V_(AUX)) 67 of auxiliary winding 41 that is divided by the voltagedivider of resistors 68 and 69. T_(RAMP) detection circuit 91 generatesfeedback signal (T_(RAMP)) 51. Delay element 90 receives feedback signal(T_(RAMP)) 51 and generates the delayed signal T_(RAMPD). The delayedsignal T_(RAMPD) is asserted at a delay T_(D2) from when feedback signal(T_(RAMP)) 51 is asserted. T_(RAMP) detection circuit 91 includes acurrent mirror 96 formed by p-channel FETs 97 and 98. When main powerswitch 44 is on and inductor current 50 is ramping up in primaryinductor 39, oscillator 42 generates a voltage-controlled-oscillatorcurrent I_(VCO) using current mirror 96. The magnitude ofvoltage-controlled-oscillator current I_(VCO) is expressed as:

$\begin{matrix}{{I_{VCO} = {{M \cdot \frac{V_{AUX}}{R_{{FB}\; 1}}} = {M \cdot \frac{V_{IN} \cdot \frac{N\; a}{N\; p}}{R_{{FB}\; 1}}}}},} & (1)\end{matrix}$

where M is the gain of current mirror 96. In one embodiment, the gain Mis one, and I_(VCO) equals the feedback current I_(FB) flowing backthrough feedback bond pad FB 66.

Oscillator capacitor C_(OSC) 95 is charged with a charge current I_(OSC)generated by current source 92. In this embodiment, oscillator capacitorC_(OSC) 95 is discharged by current source 93 at a discharge currentthat is four times as large as the charge current. Because chargingcurrent source 92 is not turned off when discharging current source 93is turned on, the discharging current is three times as large as thecharging current, as shown in FIG. 9. FMOD 82 generates a bias currentwith a voltage that is proportional to the voltage of auxiliary feedbacksignal 52 when main power switch 44 is off. Current source 92 receivesthe bias current. Oscillator 42 is powered by a five-volt power signalgenerated by regulator 72.

Oscillator 42 is an internal RC oscillator and generates switchingfrequency signal 53 whose frequency f_(OSC) is dependent on thecapacitance of oscillator capacitor C_(OSC) and the oscillatorresistance R_(OSC). The oscillator resistance can be expressed asR_(OSC)=V_(FB)/I_(OSC), where V_(FB)=V_(OUT)·Na/Ns. PWM logic 45receives switching frequency signal 53 from oscillator 42. PWM logic 45then uses switching frequency signal 53 and pulse width signal 58received from pulse width generator 49 to generate the Nchon signal 57.The frequency f_(OSC) of switching frequency signal 53 determines howoften the pulses of Nchon signal 57 occur.

FIG. 8 shows idealized waveforms of the voltage (V_(AUX)) 67 on a nodeof auxiliary winding 41, the current (I_(LP)) through primary winding39, and the current. (I_(S)) through the secondary winding as reflectedby the current through secondary-side rectifier 61 operating indiscontinuous conduction mode (DCM). Main power switch 44 turns on atT1, turns off at T2, and turns on again at T4. Thus, the time between T1and T4 is the switching period. The time between T1 and T2 is theramp-up time (T_(RAMP)) during which main power switch 44 is turned on.The time between T2 and T4 is the time during which main power switch 44is turned off. The current waveform (I_(S)) shows that the currentthrough secondary winding 40 of transformer 36 discharges to zero by T3.

Feedback signal 51 (also referred to as the voltage waveform T_(RAMP))reflects the actual ramp-up time of primary inductor 39, which isdetected by oscillator and T_(RAMP) detector 42 based on the voltage(V_(AUX)) 67 on a node of auxiliary winding 41. The voltage of auxiliaryfeedback signal 52 on feedback bond pad FB 66 provides oscillator 42with an indication of the voltage (V_(AUX)) 67 across the auxiliarywinding. When the voltage waveform (V_(AUX)) 67 goes negative and thefeedback signal 51 (voltage waveform T_(RAMP)) goes high, the currentthrough the primary inductor (I_(LP)) begins to rise, as shown in FIG.8. Oscillator 42 detects the end of the ramp-up time T_(RAMP) when theprimary inductor current (I_(LP)) reaches its peak (I_(P)) and thevoltage across the auxiliary winding (V_(AUX)) flies up.

The output power of flyback converter 30 generally depends only on thestored energy of primary inductor 39 in discontinuous conduction mode(DCM) according to an equation (2), which neglects efficiency losses:P _(OUT)=(V _(OUT) +V _(D))·I _(OUT)=½·I _(P) ² ·L _(P) ·f _(OSC)  (2)

where V_(D) is the voltage drop across secondary side rectifier 61,L_(P) is the inductance of primary winding 39, I_(P) is the peak currentof primary inductor 39, and f_(OSC) is the switching frequency as set byoscillator 42 of controller IC 38. Thus, the current output from flybackconverter 30, neglecting efficiency losses, is expressed as:

$\begin{matrix}{I_{OUT} = {\frac{\frac{1}{2} \cdot I_{P}^{2} \cdot L_{P} \cdot f_{OSC}}{V_{OUT} + V_{D}}.}} & (3)\end{matrix}$

The output voltage V_(OUT) of flyback converter 30 is the nominalregulation voltage when I_(OUT) is less than the limit (I_(LIM)) of thepeak current (I_(P)) flowing through primary winding 39. The magnitudeof the peak current limit (I_(LIM)) is pre-determined before flybackconverter 30 enters the operating mode. In the constant-output-currentoperating mode, the output voltage V_(OUT) of flyback converter 30 dropsfrom its nominal regulation voltage to zero as the output currentattempts to increase above the desired constant output current. To keepI_(OUT) constant, the switching frequency (f_(OSC)) of oscillator 42 ispreferably reduced proportionately to the voltage (V_(OUT)+V_(D)) whilemaintaining a fixed peak current (I_(P)) of primary inductor 39. Due tovariations in the peak current (I_(P)), however, the switching frequency(f_(OSC)) is also preferably varied inversely proportionately to thepeak current (I_(P)) in order to maintain a constant output current(I_(OUT)).

FIG. 9 illustrates how the inductance (L_(P)) of primary winding 39 isdynamically measured to enable the switching frequency (f_(OSC)) to bevaried to maintain a constant output current (I_(OUT)) despitevariations in the primary inductance (L_(P)). FIG. 9 is described inrelation to the various equations below. In addition, a method isdescribed for producing a switching frequency (f_(OSC)) that variesinversely with a change in the inductance (L_(P)) of primary winding 39.

The final result of the method for producing the switching frequency(f_(OSC)) is described in Equation 11. Some of the waveforms illustratedin FIG. 9 are idealized timing waveforms generated by oscillator 42 ofcontroller IC 38. The ramp voltages are developed through current sourcecharging/discharging timing capacitors. The charge current for a timingcapacitor C_(OSC) in oscillator 42 is:

$\begin{matrix}{I_{OSC} = {\frac{V_{FB}}{R_{OSC}} = {\frac{V_{OUT} + V_{D}}{R_{OSC}} \cdot \frac{N\; a}{N\; s} \cdot \frac{R_{{FB}\; 2}}{R_{{FB}\; 1} + R_{{FB}\; 2}}}}} & (4)\end{matrix}$

where, as shown in FIG. 5, Na is the number of turns of auxiliarywinding 41, Ns is the number of turns of secondary winding 40; R_(FB1)and R_(FB2) are the resistances of feedback resistors 68 and 69,respectively, R_(OSC) is the resistance of an internal IC resistor inoscillator 42 used to produce the current I_(OSC), and V_(FB) is thevoltage of auxiliary feedback signal 52 present on feedback bond pad FB66. The voltage V_(FB) on feedback bond pad FB 66 is: (a) obtained fromthe feedback voltage (V_(AUX)) 67 and is equal to(V_(OUT)·Na/Ns)·[R_(FB2)/(R_(FB1)+R_(FB2))] when main power switch 44 isoff and the current through secondary winding 40 is greater than zero,and (b) close to zero volts when main power switch 44 is on andcontroller IC 38 actively controls the voltage V_(FB). In thisembodiment, the discharge current for the oscillator timing capacitorC_(OSC) is chosen to be three times larger than the charge currentI_(OSC), as shown in FIG. 9. Other ratios are used in other embodiments.Note that the discharge current source 93 is four times larger than thecharge current source 92 in FIG. 7 in order to achieve the 3:1 ratio.The oscillator frequency (f_(OSC)) is described by the equation:

$\begin{matrix}{f_{OSC} = {\frac{1}{T} = {\frac{1}{{Tch} + {Tdisch}} = {\frac{3}{4} \cdot {\frac{I_{OSC}}{C_{OSC} \cdot V_{CO}}.}}}}} & (5)\end{matrix}$

The term V_(CO) is obtained from another timing capacitor C_(VCO) andthe charge current I_(FB). When main power switch 44 is on, the voltageof auxiliary feedback signal 52 present on feedback bond pad FB 66 isdriven close to zero by controller IC 38. Moreover, FIG. 8 shows thatwhen main power switch 44 is on, the voltage (V_(AUX)) 67 acrossauxiliary winding 41 is negative and equal to

$\begin{matrix}{V_{AUX} = {{- V_{IN}} \cdot {\frac{N\; a}{N\; p}.}}} & (6) \\{{Hence},{I_{FB} = {\frac{V_{FB} - V_{AUX}}{R_{{FB}\; 1}} = {\frac{V_{IN}}{R_{{FB}\; 1}} \cdot \frac{N\; a}{N\; p}}}},{and}} & (7) \\{V_{CO} = {\frac{V_{IN}}{R_{{FB}\; 1}} \cdot \frac{N\; a}{N\; p} \cdot {\frac{T_{RAMP}}{C_{VCO}}.}}} & (8)\end{matrix}$

Thus, the frequency output by oscillator 42 can be expressed bycombining equations (4), (5) and (8), resulting in equation (9):

$\begin{matrix}{f_{OSC} = {\frac{3}{4} \cdot \frac{V_{OUT} + V_{D}}{V_{IN} \cdot T_{RAMP}} \cdot \frac{N\; p}{N\; s} \cdot \frac{C_{VCO}}{C_{OSC}} \cdot \frac{R_{{FB}\; 1}}{R_{OSC}} \cdot {\frac{R_{{FB}\; 2}}{R_{{FB}\; 1} + R_{{FB}\; 2}}.}}} & (9)\end{matrix}$

The volt-second of the primary inductor can be expressed asV _(IN)·T_(RAMP) =L _(P) ·I _(P),  (10)

leading to the final expression for the switching frequency (f_(OSC))generated by oscillator 42,

$\begin{matrix}{{f_{OSC} = {\frac{3}{4} \cdot \frac{V_{OUT} + V_{D}}{L_{P} \cdot I_{P}} \cdot \frac{N\; p}{N\; s} \cdot \frac{C_{VCO}}{C_{OSC}} \cdot \frac{R_{{FB}\; 1}}{R_{OSC}} \cdot \frac{R_{{FB}\; 2}}{R_{{FB}\; 1} + R_{{FB}\; 2}}}},{or}} & (11) \\{{f_{OSC} = {K \cdot \frac{V_{OUT} + V_{D}}{L\;{p \cdot I_{P}}}}},} & (12)\end{matrix}$

where K is a design constant.

Equation (12) shows that the switching frequency (f_(OSC)) generated byoscillator 42 is proportional to the voltage (V_(OUT)+V_(D)) andinversely proportional to the inductance (L_(P)) of primary winding 39.Substituting equation (12) into equation (3) results inI _(OUT)=½·K·I _(P).  (13)

Equation (13) demonstrates that the current (I_(OUT)) output fromflyback converter 30 is independent of the inductance (L_(P)) of primarywinding 39. Therefore, the disclosed method of adaptively controllingthe switching frequency f_(OSC) such that f_(OSC) is inverselyproportional to L_(P) effectively produces a constant output currentthat does not change with variations in primary inductance.

Equation (13) also demonstrates that an accurate output current(I_(OUT)) of flyback converter 30 can be generated by accuratelydetermining the peak current (I_(P)) of the primary inductor.Conventionally, the peak current (I_(P)) of a converter has not beenaccurately determined. For example, the peak current (I_(P)) of theprior-art converter 25 was set using a constant reference voltage. Theconstant reference voltage was generated by using an external resistorto divide a voltage derived from a bandgap, as shown in FIG. 2A (priorart). The current sense resistor (R_(CS)) 14 sensed the current from theprimary inductor and converted it into a voltage signal that was sensed.When this voltage reached the reference voltage, it triggered a currentlimit comparator, which reset the PWM logic and turned off the mainswitch 12. This conventional method of setting the maximum primaryinductor current has some inherent errors.

FIG. 10 shows operational and timing waveforms of control loop 48 ofadaptive current limiter 43 of controller IC 38. The “N-channel on”(Nchon) waveform 57 is the on/off gate drive signal to the internalMOSFET that functions as main power switch 44. Switch signal 54(waveform I_(SW)) is the current flowing into a bond pad SW 99 ofcontroller IC 38 from the emitter of external NPN bipolar transistor 37to the drain of internal main MOSFET switch 44. The voltage waveformV_(SW) is the voltage on bond pad SW 99. The period T_(D1) is the delaytime between when Nchon 57 is asserted until the time that the current(I_(SW)) 54 through SW bond pad 99 actually begins to ramp up. The delaytime (T_(D1)) results from the switching delay in turning on externalNPN bipolar transistor 37. The current (I_(SW)) through SW bond pad 99is comprised of two component currents: (a) the actual current (I_(LP))through primary inductor 39, which is the current through the collectorof external NPN bipolar transistor 37, and (b) the base current ofbipolar transistor 37. The base current is an offset current and causesthe current (I_(SW)) of switch signal 54 to start from a non-zero value,as shown in FIG. 10 by the step in the current (I_(SW)) that occurs atthe end of the delay time (T_(D1)). Besides the base current of bipolartransistor 37, other factors also cause the current waveform (I_(LP))through primary inductor 39 to differ from the current waveform (I_(SW))through SW bond pad 99, such as parasitics associated with the drain ofmain switch 44 and propagation delays.

When oscillator 42 detects the beginning of the ramp of the inductorcurrent (I_(LP)) 50 using auxiliary feedback signal 52, oscillator 42asserts feedback signal (T_(RAMP)) 51. The time when inductor current(I_(LP)) 50 stops increasing in magnitude through primary inductor 39 isindicated in FIG. 10 as the “first time”. When feedback signal 51 isasserted, a p-channel FET is opened, allowing charge from a first fixedcurrent source (I₁) to accumulate on a first timing capacitor C1. Thecharge on first timing capacitor C1 ramps up at a rate dV_(C1)/dt=I/C1.Oscillator 42 also generates a T_(RAMPD) signal, which is a delayedversion of feedback signal (T_(RAMP)) 51. Oscillator 42 asserts theT_(RAMPD) signal after a second delay time (T_(D2)) following the end ofthe delay time (T_(D1)) . When the T_(RAMPD) signal is asserted at theend of the second delay period (T_(D2)), a second p-channel FET isopened, allowing charge from a second fixed current source (I₂) toaccumulate on a second timing capacitor C2. In the embodiment of theadaptive current limiter 43 of FIG. 6, second timing capacitor C2 ishalf the size of first timing capacitor C1. In an alternativeembodiment, first capacitor C1 and second capacitor C2 are the samesize, and second fixed current source (I₂) generates twice the currentof first fixed current source (I₁). In both embodiments, the charge(V_(C2)) on second timing capacitor C2 ramps up at precisely twice therate of the charge (V_(C1)) on first timing capacitor C1.

When the delayed T_(RAMPD) signal is asserted and charge begins toaccumulate on second timing capacitor C2, a base-current compensatedramp signal (I_(SWCOMP)) that tracks the current (I_(SW)) of switchsignal 54 on SW bond pad 99, is allowed to rise, as shown in FIG. 10.The DC base current error component in the current (I_(SW)) of switchsignal 54 has been removed from the compensated ramp signal(I_(SWCOMP)). Thus, the compensated ramp signal (I_(SWCOMP)) reflectsthe actual current (I_(LP)) through primary inductor 39 and through thecollector of bipolar transistor 37.

In the embodiment of the adaptive current limiter 43 of FIG. 6, thecompensated ramp signal (I_(SWCOMP)) is generated by capacitivelycoupling switch signal 54 on SW bond pad 99 with a coupling capacitor tocancel the DC offset component. The charge on the coupling capacitor isheld at zero with a switch until the delayed T_(RAMPD) signal isasserted. When the current of the compensated ramp signal (I_(SWCOMP))reaches one half of the pre-determined limit (I_(LIM)) of the peakcurrent flowing through primary winding 39, the charging of secondtiming capacitor C2 is halted and the voltage on capacitor C2 is held.In one implementation, the time at which I_(SWCOMP) reaches ½I_(LIM) isdetermined by comparing the voltages (V_(SWCOMP) and ½V_(LIM)) on thecorresponding nodes. The held voltage on capacitor C2 serves as thereference voltage for determining the exact time when the compensatedramp signal (I_(SWCOMP)) would have reached the limit (I_(LIM)) of thepeak current flowing through primary winding 39 had the compensated rampsignal (I_(SWCOMP)) begun to ramp up along with the current (I_(SW)) onSW bond pad 99 upon the assertion of the T_(RAMP) signal.

First timing capacitor C1 continues to charge up until the time at whichthe voltage on first timing capacitor C1 reaches the held referencevoltage on second timing capacitor C2. Timing signal 55 (also called acharge crossing signal Tcx) is asserted at the time at which the charge(V_(C1)) on first timing capacitor C1 reaches the charge (V_(C2)) onsecond timing capacitor C2. Timing signal 55 is asserted at the time thecurrent through the primary inductor (I_(LP)) reaches the peak currentlimit (I_(LIM)) because first timing capacitor C1 has charged at halfthe rate of second timing capacitor C2. Thus, timing signal 55 isasserted at the target time for reaching the peak current limit(I_(LIM)).

Next, the falling edge of feedback signal (T_(RAMP)) 51 that indicatesthe actual time at which the current (I_(LP)) through primary inductor39 has stopped increasing is compared to the rising edge of timingsignal 55. The falling edge of the T_(RAMP) signal indicates the end ofthe turn-on time when the primary inductor current (I_(LP)) has reachedits peak and the voltage across the auxiliary winding (V_(AUX)) fliesup.

FIG. 6 shows that adaptive current limiter 43 generates pulse widthsignal 58, and PWM logic 45 uses pulse width signal 58 to generate the“N-channel on” (Nchon) signal 57. Thus, the pulse width of Nchon signal57 is controlled-by pulse width generator 49 in adaptive current limiter43. Pulse width signal 58 is generated by using delay-locked-loop-typecontrol loop 48 to compare feedback signal 51 to timing signal 55.DLL-type control loop 48 includes a phase detector that generates a downpulse to increase the duty cycle of Nchon signal 57 by extending thefalling edge beyond the rising edge of timing signal 55 if the fallingedge of feedback signal 51 comes earlier than the target time at therising edge of timing signal 55. Delaying the falling edge of Nchonsignal 57 to increase the duty cycle increases the peak current (I_(P))through primary inductor 39 on the next switching cycle. Conversely, ifthe falling edge of feedback signal 51 comes later than the target timeat the rising edge of timing signal 55, the phase detector of controlloop 48 generates an up pulse that decreases the duty cycle of Nchonsignal 57 by advancing the falling edge so that it falls before therising edge of timing signal 55. Advancing the falling edge of Nchonsignal 57 to decrease the duty cycle reduces the peak current (I_(P))through primary inductor 39 on the next switching cycle. Control loop 48thereby maintains a constant peak current (I_(P)) of primary inductor 39at the pre-determined value I_(LIM).

It is apparent from FIG. 10 that the magnitude of the second delay time(T_(D2)) between when feedback signal 51 is asserted and when thedelayed T_(RAMPD) signal is asserted does not influence the time atwhich the compensated ramp signal (I_(SWCOMP)) reaches one half of thepre-determined limit (I_(LIM)) of the peak current flowing throughprimary winding 39, so long as the second delay time (T_(D2)) is lessthan half the time it takes for the compensated ramp signal (I_(SWCOMP))to reach ½I_(LIM). This is true because it is the voltage level (V_(C2))on second timing capacitor C2, as opposed to the exact moment that thecompensated ramp signal (I_(SWCOMP)) reaches ½I_(LIM), that determineswhen the charge on the first timing capacitor C1 will cross thereference voltage level (V_(C2)) established on second timing capacitorC2.

When control loop 48 of adaptive current limiter 43 adjusts timingsignal 55 such that the rising edge of timing signal 55 occurs at thesame time as the falling edge of feedback signal 51, the peak current(I_(P)) of primary inductor 39 is made equal to the pre-determined limit(I_(LIM)) of the peak current. Control loop 48 matches the peak current(I_(P)) to the pre-determined limit (I_(LIM)) largely independently ofinput line voltage, temperature, process variations, component tolerancechanges, and PCB layout variations.

From another perspective, the internal main MOSFET switch 44 is turnedon for a period equaling the time T1 for the compensated ramp signal(I_(SWCOMP)) to reach ½I_(LIM) plus a width-change time (T_(WIDTH)). Thewidth-change time (T_(WIDTH)) refers to a change in the pulse width ofNchon signal 57. Main power switch 44 is turned on at the beginning ofeach oscillator cycle based on the switching frequency (f_(OSC))generated by oscillator 42 and is turned off at the end of the period(T1+T_(WIDTH)), where T_(WIDTH) is adjusted by control loop 48 SO thatthe total ramp-up time equals the expected ramp-up time, and constantoutput current is maintained.

FIG. 11 shows a more detailed diagram of adaptive current limiter 43 ofcontroller IC 38. Adaptive current limiter 43 includes comparing circuit47, control loop 48 and voltage controlled pulse width generator 49.Pulse width generator 49 includes a one-shot generator 100 thatgenerates a pulse at the appropriate pulse width of Nchon signal 57.Control loop 48 includes a phase detector 101, a charge pump 102 and aloop filter 103. Control loop 48 resembles a delay-locked-loop (DLL) andsynchronizes feedback signal (T_(RAMP)) 51 to timing signal 55 SO thatpulse width generator 49 can generate pulse width signal 58. Phasedetector 101 includes two D-flip-flops 104 and 105 and a NAND gate 106.Charge pump 102 includes two switches 107 and 108 and two currentsources 109 and 110. Loop filter 103 includes a resistor 111 and acapacitor 112 that generate the filter voltage V_(FILTER) of time errorsignal 59. One-shot generator 100 of pulse width generator 49 is setwhen the compensated ramp signal (I_(SWCOMP)) crosses the referencecurrent ½I_(LIM) and is cleared when a one-shot timer 113 expires. Theone-shot pulse is generated after the elapse of a time period that isinversely proportional to the filter voltage V_(FILTER) of time errorsignal 59 and proportional to the time period between the falling edgeof feedback signal 51 and the rising edge of timing signal 55.

Adaptive current limiter 43 also includes first timing capacitor (C1)114, second timing capacitor (C2) 115, three timing bias-current sources116-118, a first comparator 119, a second comparator 120, two p-channelFETs 121-122, an n-channel FET 123, a capacitor 124 and a sense resistor(R_(SENSE)) 125. First timing capacitor (C1) 114 is twice as large assecond timing capacitor (C2) 115.

When the current (I_(LP)) through primary winding 39 begins to ramp upand feedback signal 51 is asserted, p-channel FET 121 turns off, andtiming bias-current source 117 begins to charge first timing capacitor(C1) 114. Thus, the charge (V_(C1)) on first timing capacitor C1 rampsup, as shown in FIG. 10. After the second delay time (T_(D2)), thedelayed T_(RAMPD) signal is asserted, and p-channel FET 122 turns off,allowing timing bias-current source 118 to begin charging second timingcapacitor (C2) 115. The slew rate of capacitor (C2) 115 is twice that ofcapacitor (C1) 114 because capacitor (C2) 115 is half the size ofcapacitor (C1) 114.

When the delayed T_(RAMPD) signal is asserted, the n-channel FET 123also turns off, and the base-current compensated ramp signal(I_(SWCOMP)) is generated on the non-inverting input lead of firstcomparator 119 by using capacitor 124 to remove the DC offset of thecurrent (I_(SW)) of switch signal 54 caused by the base current ofexternal bipolar transistor 37. First comparator 119 then compares thevoltage (V_(SWCOMP)) corresponding to compensated ramp signal(I_(SWCOMP)) to a voltage ½V_(LIM) corresponding to the referencecurrent ½I_(LIM) that is generated by timing bias-current source 116 anda resistor 126. In another implementation, instead of using firstvoltage comparator 119, compensated ramp signal (I_(SWCOMP)) is compareddirectly to the reference current ½I_(LIM) using a current comparatorwith sense FETs. When the compensated ramp signal (I_(SWCOMP)) reachesthe reference current ½I_(LIM), first comparator 119 asserts a tripsignal that turns off a p-channel FET 127 and thereby turns off timingbias-current source 118. When timing bias-current source 118 is turnedoff, the charge (V_(C2)) on second timing capacitor (C2) 115 is held.The charge (V_(C1)) on first timing capacitor (C1) 114, however,continues to ramp up at half the rate of the charging of second timingcapacitor C2. Second comparator 120 compares the rising charge (V_(C1))on first timing capacitor C1 to the held charge (V_(C2)) on secondtiming capacitor C2. When the rising charge (V_(C1)) reaches the heldvoltage (V_(C2)) on second timing capacitor C2, the target time isreached, and second comparator 120 asserts timing signal 55. Phasedetector 101 uses the rising edge of timing signal 55 as the moment thatthe current (I_(LP)) through primary inductor 39 should equal thedesired pre-determined limit (I_(LIM)) of the peak current (I_(P))flowing through primary inductor 39.

In the embodiment of FIG. 11, the relative sizes of the first and secondtiming capacitors 114-115 are used to generate the correct timing intiming signal. 55. Other circuit topologies, however, can also be usedto achieve the correct timing ratios. For example, equal-sized timingcapacitors can be used with a first current source 117 that generateshalf the current of a second current source 118. Alternatively, secondcomparator 120 can be made to assert timing signal 55 when the risingcharge (V_(C1)) is twice as large as the held voltage (V_(C2)), and thetiming capacitors and current sources are the same size.

In the embodiment of FIG. 11, the filter voltage V_(FILTER) generated bycontrol loop 48 is used as time error signal 59 to reflect the timedifference between the falling edge of feedback signal 51 and the risingedge of timing signal 55. The rising edge of timing signal 55 isgenerated based on the time it takes for the compensated ramp signal(I_(SWCOMP)) to reach the pre-determined fixed reference current½I_(LIM). In another embodiment, the filter voltage V_(FILTER) is usedto adjust the reference current ½I_(LIM) produced by current source 116and resistor 126 such that second timing capacitor (C2) 115 reaches areference voltage simultaneously with first timing capacitor (C1) 114.In such an embodiment, an adjustable reference current ½I_(LIM) isincreased when the falling edge of feedback signal 51 comes before therising edge of timing signal 55, indicating the need to increase thepeak current (I_(P)) through primary inductor 39. Correspondingly, theadjustable reference current ½I_(LIM) is decreased when the falling edgeof feedback signal 51 comes after the rising edge of timing signal 55,indicating the need to decrease the peak current (I_(P)).

In yet another embodiment, the switching frequency (f_(OSC)) ofoscillator 42 is adjusted based on time error signal 59 in order togenerate a constant output current I_(OUT) of flyback converter 30. Theswitching frequency (f_(OSC)) is adjusted by adjusting the oscillatorcurrent I_(OSC) for a given oscillator timing capacitance C_(OSC)according to equation (5). The oscillator current I_(OSC) is adjusted byadjusting the resistance R_(OSC) of an internal IC resistor inoscillator 42. Equation (3) above shows that I_(OUT) is proportional tothe switching frequency (f_(OSC)) of oscillator 42. Thus, by adjustingthe switching frequency (f_(OSC)) using the time error signal 59 derivedfrom the delay between the target time and the falling edge of feedbacksignal 51, the output current I_(OUT) is held constant despitevariations in the peak current (I_(P)) of primary inductor 39. Note thatin equation (3), the output current I_(OUT) is proportional to thesquare of the peak current (I_(P)) of primary inductor 39 and,therefore, the switching frequency (f_(OSC)) must be adjusted inverselyproportionally to the square of the peak current (I_(P)) in order tomaintain a constant output current (I_(OUT)).

In a further embodiment, the output range of PWM error amplifier 76 isadaptively adjusted using the time error signal 59 derived from thedelay between the target time and the falling edge of feedback signal 51in order to maintain a constant output current I_(OUT). When flybackconverter 30 operates in normal constant-voltage mode, the voltage oferror amplifier output signal 77 output by PWM error amplifier 76 isproportional to the output current (I_(OUT)). Moreover, inconstant-voltage mode the on-time of the main power switch 44, asreflected by the time period T_(RAMP) in FIG. 8, is controlled by thevoltage signal output by current sense amplifier 85 and error amplifieroutput signal 77. The voltage of error amplifier output signal 77 outputby error amplifier 76 increases as output current I_(OUT) increases,thus maintaining a constant output voltage.

Typically, main power switch 44 is turned on at the start of each clockcycle, and the voltage signal output by current sense amplifier 85 rampsup proportionally to the current (I_(LP)) through the primary inductor,which itself ramps up a the rate dI/dt=V_(P)/L_(P), where V_(P) is thevoltage across the primary inductor. The main power switch 44 is turnedoff when the voltage signal output by current sense amplifier 85 reachesthe voltage of error amplifier output signal 77 output by PWM erroramplifier 76. The peak current (I_(P)) of the primary inductor can belimited by clamping the voltage of regulation signal 86 output by errorcomparator 81 at a maximum level. Thus, the peak current (I_(P)) limitcan be controlled by adjusting this clamp voltage of regulation signal86. Time error signal 59 generated by control loop 48 is used adaptivelyto control the clamp voltage to maintain a constant output current(I_(OUT)). In this embodiment, whether flyback converter 30 isregulating a constant output voltage or a constant output current, thetime at which main power switch 44 is turned off is always determined bythe intersection of the voltage signal output by current sense amplifier85 and the voltage of error amplifier output signal 77 output by PWMerror amplifier 76. In a steady-state constant-voltage mode of operationof flyback converter 30, the voltage of error amplifier output signal 77falls within its normal range below the clamp voltage, whereas in theconstant-current mode, the voltage of error amplifier output signal 77is clamped at a maximum level to limit peak current (I_(P)). In theconstant-current mode, and the clamp level is adaptively adjusted bycontrol loop 48 to control the time period T_(RAMP) in order to maintaina constant output current (I_(OUT)).

Although the present invention has been described in connection withcertain specific embodiments for instructional purposes, the presentinvention is not limited thereto. In addition to providing adaptiveprimary inductor peak current limiting, other embodiments employadaptive primary inductance compensation. Moreover, as opposed to theembodiment of FIG. 5 that uses external high-voltage NPN bipolartransistor 37 in an emitter switching configuration, other embodimentsdirectly drive primary winding 39 using an internal high-voltage powerswitch in controller IC 38. In addition, a MOSFET instead of a bipolartransistor can be used as the external switch in order further toincrease the power handling capability and switching frequency offlyback converter 30.

FIG. 12 shows an alternative embodiment of a PWM controller IC chip 128.Controller IC 128 does not include an internal main MOSFET switch, asmaller current sensing internal MOSFET, or a current sensing resistorcoupled to the current sensing MOSFET. In this embodiment, the currentdriving capability of gate driver 46 results in improved control forlarger MOSFETs.

FIG. 13 shows the alternative embodiment of flyback converter 30 thatincludes controller IC chip 128 of FIG. 12. The alternative embodimentof flyback converter 30 includes an external MOSFET 129 and a currentsense resistor 130.

FIG. 14 shows flyback converter 30 with controller IC 38 in anintegrated circuit package 131. By using only auxiliary feedback signal52 to provide feedback to control the output current and voltage offlyback converter 30, controller IC 38 can be packaged in an integratedcircuit package having only four terminals. Each terminal of anintegrated circuit package adds cost. Thus, it is less expensive toproduce controller IC 38 packaged in integrated circuit package 131 thanit is to produce controller ICs requiring packages with more than fourterminals. Integrated circuit package 131 has only four terminals: aswitch terminal 132, a feedback terminal 133, a power terminal 134 and aground terminal 135. In the embodiment of FIG. 14, switch terminal 132is connected to bond pad SW 99 by a bond wire 136. Switch signal 54 isreceived onto switch terminal 132 and then travels over bond wire 136 tobond pad SW 99. Depending on the type of package, switch terminal 132can be a lead of a quad flat pack, a land of a land grid array (LGA), apin of a pin grid array (GPA), a pin of a dual in-line package (DIP) ora pin of a single in-line package. In an embodiment in which integratedcircuit package 131 is a ball grid array package and controller IC 38 ispackaged in a flip-chip manner, switch terminal 132 is not connected tobond pad SW 99 by a bond wire. In a ball-grid-array embodiment, there isa bump on bond pad SW 99, and switch terminal 132 is a bond ballconnected to the bump. In various embodiments, feedback terminal 133,power terminal 134 and ground terminal 135 can likewise be bond balls ofa ball grid array, leads of a quad flat pack, lands of a land grid array(LGA), pins of a pin grid array (GPA), pins of a dual in-line package(DIP) or pins of a single in-line package. In embodiments in whichfeedback bond pad FB 66 is connected to feedback terminal 133 by a bondwire 137, controller IC 38 receives an indication of the output voltage(V_(OUT)) of secondary winding 40 via feedback terminal 133. Auxiliaryfeedback signal 52 is received onto feedback terminal 133 and thentravels over bond wire 137 to feedback bond pad FB 66.

Although pulse-width-modulation (PWM) logic 45 is described above asemploying pulse width modulation in the generation of Nchon signal 57and inductor switch control signal 56, variable frequency modulation canbe used as an alternative to fixed frequency PWM. In alternativeembodiments, variable-frequency pulse frequency modulation (PFM) is usedto generate Nchon signal 57 and inductor switch control signal 56.

Accordingly, various modifications, adaptations, and combinations ofvarious features of the described embodiments can be practiced withoutdeparting from the scope of the invention as set forth in the claims.

1. The method comprising: (a) receiving a feedback signal indicative ofa first time, wherein an inductor current flowing through an inductorstops increasing at the first time; (b) receiving a switch signalindicative of a ramp-up rate at which the inductor current increases;(c) generating a timing signal that indicates a target time at which theinductor current would reach a predetermined current limit if theinductor current continued to increase at the ramp-up rate; (d)generating an inductor switch control signal that has a pulse width; and(e) controlling the pulse width of the inductor switch control signalsuch that the first time and the target time occur simultaneously. 2.The method of claim 1, wherein the controlling in (e) decreases thepulse width when the first time occurs after the target time.
 3. Themethod of claim 1, wherein the inductor is a primary winding of aflyback converter.
 4. The method of claim 3, wherein the flybackconverter outputs an output current, wherein the inductor exhibits aninductance whose magnitude deviates from a stated nominal magnitude, andwherein the inductor switch control signal has a switching frequency,further comprising: (f) controlling the switching frequency tocompensate for the deviating magnitude of the inductance and to maintaina constant output current.
 5. The method of claim 4, wherein thecontrolling in (f) is performed by an integrated circuit that ispackaged in an integrated circuit package having no more than fourterminals.
 6. The method of claim 1, wherein the controlling in (e) isperformed by an integrated circuit that is packaged in an integratedcircuit package having no more than four terminals.
 7. The method ofclaim 1, wherein the feedback signal is generated using a voltage acrossan auxiliary inductor, and wherein the auxiliary inductor ismagnetically coupled to the inductor.
 8. The method of claim 1, whereinthe inductor switch control signal has a switching frequency, furthercomprising: (f) decreasing the switching frequency when the first timeoccurs after the target time.
 9. The method of claim 1, wherein thetiming signal is generated in (c) using a current comparator.
 10. Amethod comprising: (a) receiving a feedback signal indicative of a firsttime, wherein an inductor current flowing through an inductor stopsincreasing at the first time; (b) receiving a switch signal indicativeof a ramp-up rate at which the inductor current increases; (c)generating a timing signal that indicates a target time at which theinductor current would reach a predetermined current limit if theinductor current continued to increase at the ramp-up rate; (d)generating an inductor switch control signal that has a pulse width; and(e) controlling the pulse width of the inductor switch control signalsuch that the first time and the target time occur simultaneously,wherein the timing signal is generated in (c) by comparing charge thataccumulates on timing capacitors of different sizes.
 11. A methodcomprising: (a) receiving a feedback signal indicative of a first time,wherein an inductor current flowing through an inductor stops increasingat the first time; (b) receiving a switch signal indicative of a ramp-uprate at which the inductor current increases; (c) generating a timingsignal that indicates a target time at which the inductor current wouldreach a predetermined current limit if the inductor current continued toincrease at the ramp-up rate; (d) generating an inductor switch controlsignal that has a pulse width; and (e) controlling the pulse width ofthe inductor switch control signal such that the first time and thetarget time occur simultaneously, wherein the timing signal is generatedin (c) by comparing charge that accumulates on same-sized timingcapacitors that are charged by current sources of different sizes.
 12. Adevice comprising: an inductor switch that is controlled by an inductorswitch control signal, wherein the inductor switch control signal has apulse width; an inductor, wherein an inductor current flowing throughthe inductor increases at a ramp-up rate during a ramp time, wherein theramp time ends at a first time, and wherein the inductor current stopsincreasing at the first time; a comparing circuit that generates atiming signal, wherein the timing signal indicates a target time atwhich the inductor current would reach a predetermined current limit ifthe inductor current continued to increase at the ramp-up rate; and acontrol loop that receives the timing signal and compares the first timeto the target time.
 13. The device of claim 12, wherein the inductor isa primary winding of a flyback converter.
 14. The device of claim 13,wherein the flyback converter outputs an output current, wherein theinductor switch control signal has a frequency, and wherein the deviceadjusts the frequency such that the output current remains constant. 15.The device of claim 12, wherein the device controls the inductor currentsuch that the inductor current reaches the predetermined current limitat the first time.
 16. The device of claim 12, wherein the inductorswitch, the comparing circuit and the control loop are all part of anintegrated circuit that is packaged in an integrated circuit packagehaving no more than four terminals.
 17. The device of claim 12, furthercomprising: a pulse width generator that generates a pulse width signal,wherein the pulse width signal controls the pulse width of the inductorswitch control signal, and wherein the pulse width generator increasesthe pulse width when the first time occurs before the target time. 18.The device of claim 12, further comprising: an oscillator that generatesa switching frequency signal, wherein the switching frequency signal hasa frequency, and wherein the inductor switch control signal has afrequency that depends on the frequency of the switching frequencysignal.
 19. A device comprising: an inductor switch that is controlledby an inductor switch control signal, wherein the inductor switchcontrol signal has a pulse width; an inductor, wherein an inductorcurrent flowing through the inductor increases at a ramp-up rate duringa ramp time, wherein the ramp time ends at a first time, and wherein theinductor current stops increasing at the first time; a comparing circuitthat generates a timing signal, wherein the timing signal indicates atarget time at which the inductor current would reach a predeterminedcurrent limit if the inductor current continued to increase at theramp-up rate, wherein the comparing circuit comprises a timing capacitorand generates a compensated inductor current, and wherein the comparingcircuit determines a reference voltage to which the timing capacitorcharges when the compensated inductor current has reached apredetermined proportion of the predetermined current limit; and acontrol loop that receives the timing signal and compares the first timeto the target time.
 20. The device of claim 19, wherein a current flowsthrough the inductor switch, and wherein the comparing circuit generatesthe compensated inductor current using the current that flows throughthe inductor switch.
 21. The device of claim 19, wherein thepredetermined proportion is one half.
 22. A system comprising: aninductor; a switch, wherein a current increases at a ramp-up ratethrough the inductor when the switch is turned on, and wherein thecurrent reaches a maximum magnitude and stops increasing at a first timewhen the switch is turned off; and means for controlling the time whenthe switch is turned off such that the maximum magnitude reached at thefirst time when the switch is turned off equals a predetermined currentlimit, wherein the means compares the first time when the switch isturned off to a target time at which the current would reach thepredetermined current limit if the current continued to increase at theramp-up rate.
 23. The system of claim 22, wherein the means includes acontrol loop.
 24. The system of claim 22, wherein the system is aflyback converter with a primary side and a secondary side, wherein theflyback converter has an auxiliary winding on the primary side and asecondary winding on the secondary side, wherein feedback from thesecondary side that is used by the means to control the first time whenthe switch is turned off, and wherein the feedback is obtained solelyfrom magnetic coupling of the auxiliary winding and the secondarywinding.
 25. The system of claim 22, wherein the means is part of anintegrated circuit that is packaged in an integrated circuit packagehaving no more than four terminals.